Filter and method of making

ABSTRACT

A filter formed by the following steps is provided. The steps including: forming a plurality of sheets of filter media, each sheet of filter media having an inlet end and an outlet end, wherein each of the plurality of sheets of filter media are formed by the steps of: thermoforming a first layer of filtration media to have a plurality of channels, the first layer having an upper surface and a lower surface; sonically welding a portion of a second layer of filtration media to the first layer of filtration media after the first layer is thermoformed to form the sheet of filtration media, wherein at least one edge of the first layer is not sonically welded to at least one edge of the second layer, wherein the sheet of filtration media has a plurality of fluid channels each having an inlet opening at the at least one edge of the first layer and the second layer and a sealed end at another end of the sheet; and securing the plurality of sheets together by applying a strip of adhesive between each upper surface of each first layer facing the second layer of another sheet of filter media stacked upon the upper surface of the first layer of the filtration media.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. Ser. No. 11/533,649filed Sep. 20, 2006 now U.S. Pat. No. 7,794,556 which claims the benefitof U.S. Provisional patent ppplication No. 60/718,639 filed Sep. 20,2005, the contents each of which are incorporated herein by referencethereto.

TECHNICAL FIELD

The present invention relates to a filter for a fluid and a method formaking the same.

BACKGROUND

Air induction housing systems are continually being challenged to becomesmaller and unique in shape without loss of system performance. Inparticular and referring to vehicular applications, this is due in partto the reduction in available real estate in the engine compartment. Asvehicle profiles are reduced and engine systems become more complexthere is very little available space for the air induction system, whichis a critical component of the engine. The air induction system in aninternal combustion engine of a vehicle provides at least two importantfunctions; providing a means for delivery of air into the combustionchambers of the engine and providing a means for filtering the air priorto its delivery to the combustion chambers. Due to its filteringfunction the filter itself needs to be replaced after an extended periodof use thus, accessibility to the filter is also a requirement imposedupon the air induction system as well as the housing.

In some designs the air induction system is not designed until theengine design is completed thus, the designers of the air inductionsystem are typically faced with the problem of providing a predeterminedamount of airflow to the engine while also being presented with alimited or unique amount of space between the engine and the vehiclehood, front grill etc. Accordingly, the air induction housing typicallyhas a unique configuration that is optimized for flow and spacerequirements, which may be contradictory to design requirements for thefilter to be located with in the air induction system.

Furthermore, reducing the housing size and creating unique shapes limitsthe overall size of the filter capable of being disposed therein.Accordingly, and based upon conventional airflow technology, smallerfilters typically result in less capacity thus, reduced performance.

Accordingly, it is desirable to provide a filter and method ofmanufacture wherein the filter is capable of providing increasedcapacity while also accommodating the reduced size and shape limits.Moreover, it is also desirable to provide a filter and method ofmanufacture wherein the filter is configured for use as an air filter,fluid filter, fuel filter, oil filter, coolant filter, etc.

SUMMARY OF THE INVENTION

A filter formed by the following steps is provided. The steps including:forming a plurality of sheets of filter media, each sheet of filtermedia having an inlet end and an outlet end, wherein each of theplurality of sheets of filter media are formed by the steps of:thermoforming a first layer of filtration media to have a plurality ofchannels, the first layer having an upper surface and a lower surface;sonically welding a portion of a second layer of filtration media to thefirst layer of filtration media after the first layer is thermoformed toform the sheet of filtration media, wherein at least one edge of thefirst layer is not sonically welded to at least one edge of the secondlayer, wherein the sheet of filtration media has a plurality of fluidchannels each having an inlet opening at the at least one edge of thefirst layer and the second layer and a sealed end at another end of thesheet; and securing the plurality of sheets together by applying a stripof adhesive between each upper surface of each first layer facing thesecond layer of another sheet of filter media stacked upon the uppersurface of the first layer of the filtration media.

In another exemplary embodiment, a filter formed by the following stepsis provided. The steps including: thermoforming a first layer offiltration media to have a plurality of channels, the first layer havingan upper surface and a lower surface; sonically welding only a portionof a second layer of filtration media to the first layer of filtrationmedia to form a sheet of filtration media having a plurality of fluidchannels defined in part by the plurality of channels, each of theplurality of fluid channels having an inlet opening at one end of thesheet that is defined by another portion of the first layer that is notsonically welded to the second layer of filtration media and a sealedend at another end of the sheet; applying a strip of adhesive to theupper surface of the first layer of filtration media; and securing thesecond layer to the upper surface of the first layer of filtration mediaby wrapping the sheet of media around itself.

In another exemplary embodiment, a filter formed by the following stepsis provided. The steps including: forming a plurality of sheets offilter media, each sheet of filter media having an inlet end and anoutlet end, wherein each of the plurality of sheets of filter media areformed by the steps of: thermoforming a first layer of filtration mediato have a plurality of channels, the first layer of filtration mediahaving an upper surface and a lower surface; ultrasonically welding onlya portion of a second layer of filtration media to the first layer offiltration media to form the sheet of filtration media, the sheet offiltration media having a plurality of fluid channels defined in part bythe plurality of channels in the first layer of filtration media andeach of the plurality of fluid channels having an inlet opening atanother portion of the second layer that is not ultrasonically welded tothe second layer and a sealed end defined at the portion where thesecond layer is ultrasonically welded to the first layer and wherein thefirst layer of filtration media and the second layer of filtration mediaare disposed between one of a pair of geared rollers and a contactsurface of a first welding horn and a second welding horn, the firstwelding horn providing welded portions of the plurality of fluidchannels and the second welding horn providing the sealed end; andsecuring the plurality of sheets together by applying a strip ofadhesive between each upper surface of each first layer facing thesecond layer of another sheet of filter media stacked upon the uppersurface of the first layer of the filtration media.

The above-described and other features are appreciated and understood bythose skilled in the art from the following detailed description,drawings, and appended claims.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of portions of a filter being constructedin accordance with exemplary embodiments of the present invention;

FIGS. 2 and 3 are perspective views illustrating construction of afilter in accordance with an exemplary embodiment of the presentinvention;

FIGS. 4-6 are perspective views of a portion of a filter constructed inaccordance with one exemplary embodiment of the present invention;

FIGS. 7-9 are views illustrating a filter constructed in accordance withanother exemplary embodiment of the present invention;

FIG. 10 illustrates portions of a roller mechanism and ultrasonicwelding mechanism used in an exemplary embodiment of the presentinvention;

FIG. 11 is a side view of a sheet of media formed by the mechanism ofFIG. 10;

FIGS. 12-14 illustrate alternative exemplary embodiments of the presentinvention;

FIG. 15 illustrates portions of a roller mechanism and ultrasonicwelding mechanism used in an alternative exemplary embodiment of thepresent invention;

FIG. 16 is a side view of a sheet of media formed by the mechanism ofFIG. 15;

FIGS. 17 and 18 are end views of a filter media constructed inaccordance with exemplary embodiments of the present invention; and

FIG. 19 is a schematic illustration of an alternative exemplaryembodiment of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

In accordance with exemplary embodiments of the present invention, afilter and method of making a filter is disclosed. In an exemplaryembodiment the filter will be comprised of a plurality of layers ofmedia each being formed by a pair of non-woven materials secured to eachother wherein one of the non-woven materials is formed to have aplurality of corrugations and the other is a planar member welded to thelayer having a plurality of corrugations and thereafter the two layersare secured to each other in order to provide a larger amount of filtersurface area. In one embodiment, a plurality of these layers are securedto each other. In another embodiment, a single layer is wrapped aroundis wrapped around itself to provide the filter. In yet another exemplaryembodiment, a single layer is wrapped around is wrapped around itselfand other separate sheets are secured to the single layer wrapped arounditself to provide the filter. In accordance with exemplary embodimentsof the present invention a high capacity honeycomb style air filter isprovided.

Reference is made to the following U.S. Pat. Nos. 6,673,136; 5,820,646;4,410,427; and 4,589,983, the contents of which are incorporated hereinby reference thereto.

Exemplary embodiments will provide an air filtration component thatenables high contaminant capacity per packing volume available. Ofcourse, it is understood that the filter may be used to filter otherfluids such as but not limited to oils, fuels, coolants, liquids andother gases. In accordance with an exemplary embodiment, a non-wovenmedia is used to provide a top or first sheet that is formed into acorrugated layer, and then the first sheet is attached to another flatsheet of the non-woven media and then this two sheet layer is used toform a filter, which provides a greater amount of media that can befitted into a given packaging space thus giving a greater dust capacityof the filter, which in the aforementioned application is an air filter.

In one non-limiting exemplary embodiment the top sheet or first sheetcontaining the corrugations is formed to have the corrugations by athermoforming process of a synthetic non-woven media. Alternatively, andif a cellulose based media is used, an embossing process could be usedto form the corrugations and other means of sealing the two layers maybe used other than sonic welding (e.g., adhesives, hot melt adhesives,etc.). Regardless of the material used and the process for forming thecorrugations, the corrugations would be formed prior to the attachmentof the lower or second flat sheet of media.

In one embodiment, the forming of the corrugations should be taperedgradually to pinch down to a flat portion on one side of the sheet toenable the attachment by welding of the lower flat sheet. In anotherexemplary embodiment, the attachment of the two sheets together alongone peripheral edge will create the flat portion. In accordance with anexemplary embodiment, this end or peripheral edge will provide a portionof the exit end of the filter.

In accordance with exemplary embodiments of the present invention thetwo sheets can be bonded together along one edge portion using anadhesive or in an exemplary embodiment a continuous sonic weld. In onenon-limiting exemplary embodiment, the sonic weld is provided by anultrasonic welding horn configured to engage an end portion of thesheets of media.

Once the two sheets are attached together a long continuous roll offilter media comprising the two layers is formed. In one exemplaryembodiment the continuous roll of media can be wrapped around itself ina spiral pattern to form a filter media. During this wrapping process, abead of adhesive will be applied on the edge opposite the flat edge(e.g., exit side) of the two layers in order to secure the layers toeach other as well as provide a sealing means in order to provide aplurality of fluid paths wherein fluid passing therethrough is filteredby the media having an inlet end and an outlet end, wherein fluid flowfrom the inlet end to the outlet end is filtered by the media. By havingalternative ends of the corrugations on each subsequent layer sealed, aflow path is created which utilizes the entire media area. In accordancewith an exemplary embodiment, the final shape of the media could beround, elliptical, oval or any number of the regular configurations.

In another exemplary embodiment, the continuous sheet or roll of mediais cut into a plurality of sheets, which are stacked and secured to eachother to provide the filter media. In any of the aforementionedembodiments, the media whether stacked, rolled, or any combinationthereof is configured to be received within a filter housing (e.g., air,oil, fuel, coolant, water, liquids, etc.) wherein the filter has aninlet end and in outlet end wherein fluid flow is filtered by the mediaby flowing through the same by passing through into the inlet end andout the outlet end.

Referring now to FIG. 1 a flat sheet or first layer of non-woven media10 is shown being inserted between two geared rollers 12 and 14. Each ofthe geared rollers have a plurality of teeth 16, 18 configured to form aplurality of channels 20 in sheet 10 as it is passed between gearedrollers 12 and 14. In accordance with an exemplary embodiment non-wovenmedia 10 is commercially available from Hollingsworth & Vose as BW3, a 3oz/yd² polyester non-woven media. In addition, other non-woven mediasfrom Hollingsworth & Vose were used including—BW4 (4 oz) and 7322 (highloft) media. Of course, other alternative materials are contemplated foruse in exemplary embodiments one non-limiting example is a cellulosebased media or other synthetic media.

In accordance with an exemplary embodiment, sheet 10 is heated prior toit being inserted between each of the geared rollers. In onenon-limiting exemplary embodiment the sheet is heated by a heat gun 22.Thus, a thermoforming process is used to form the plurality of channelsas sheet 10 passes between geared rollers 12 and 14. Of course, otherequivalent methods for heating sheet 10 are contemplated in accordancewith exemplary embodiments of the present invention. One non-limitingexample would be to provide a source of heat directly to one or both ofthe geared rollers. For example, an electric heater could be disposed ineither or both of the geared rollers.

Referring now to FIGS. 1-3, the method of securing a second layer 24 ofnon-woven media to first layer 10 is illustrated. As illustrated, thefirst layer is formed between rolls 12 and 14 and then a shield 25directs first layer 24 to travel in a direction opposite to the inletdirection (e.g., the direction the first layer is inserted between rolls12 and 14. In accordance with an exemplary embodiment shield 25 isdisposed in a facing spaced relationship with gear 14 to redirect layer10 after it has passed through the two rollers. Thus, and after layer 10is redirected a lower surface of layer 10 is now inverted to be facinglayer 24 as it is passed onto layer 10.

In accordance with an exemplary embodiment and after layer 10 isredirected by shield 25, layer 10 is secured to layer 24 by anultrasonic welding process. As is known in the related arts ultrasonicwelding is a process wherein two items (e.g., plastic, metal, etc.) arejoined together seamlessly through high-frequency acoustic vibrationswhere one component to be welded is placed upon a fixed anvil and thesecond component being placed on top and an extension (“horn”) connectedto a transducer is lowered down onto the top component, and a very rapid(˜20,000 KHz), low-amplitude acoustic vibration is applied to thewelding zone. The acoustic energy is converted into heat energy byfriction, and the parts are welded together in less than a second.

In accordance with an exemplary embodiment a sonic welding horn 26 islowered down onto second layer 24 and sonically welds a lower surface 28of channels 20 to second layer 24 by compressing layers 10 and 24between a contact surface 30 of welding horn 26 and a contact surface 31of the gears of roller 14. As used herein “lower surface” of layer 10 isintended to mean the surface that is facing downwardly when layer 10 isinserted between rollers 12 and 14 and thereafter is facing upwardlytowards layer 24 when layer 10 is redirected by shield 25. In otherwords, the edges of each of the corrugations or channels formed by theforming process on surface 28 are now secured to a surface of layer 24.For example, and if the channels are formed to have a triangularconfiguration the peak or valley 29 (depending on the orientation of thelayer) is secured via an ultrasonic weld to a portion of layer 24. Thispoint of securement is identified by reference numeral 29. Moreover,contact surface 31 provides for one of the surfaces for welding of peak29 to a portion of layer 24, the other surface being surface 30 of horn26. Of course, it is understood that the channels may have any otherconfiguration and exemplary embodiments of the present invention are notlimited to triangular configurations. Other non-limiting configurationsinclude curves, trapezoids rectangles, arcs etc.

In accordance with an exemplary embodiment, contact surface 31 of theteeth of roller 14 provides the contact surface the welding horn is ableto sandwich and secure portions of layers 10 and 24 to each other inorder to provide the fluid conduits of the sheet of the filter media.

In accordance with an exemplary embodiment and referring now to FIGS.1-3 and 10-11 and in order to provide a sealed exit end of the sheet ofmedia a peripheral edge portion of the two layers is sealed together byan ultrasonic welding method wherein another ultrasonic welding horn 33is positioned to sandwich a portion of layers 10 and 24 between theteeth of geared roller 14.

In order to provide the sealed end a surface of the ultrasonic horn 33is configured to mesh with the teeth or gears of roller 12 to seal theperipheral edge of the two layers together as well as pinch down thechannels of sheet 10.

In an alternative exemplary embodiment, sheet 10 is secured to sheet 24via an adhesive or a combination of an adhesive and the ultrasonicwelding process.

Referring now to FIGS. 1-6 and once first layer 10 is secured to secondlayer 24, a sheet of filter media 32 is formed with a plurality ofchannels each having an inlet flow opening or openings, which is formedby the openings of each of the channels formed by layer 10 and 24 toprovide an inlet end 34 and a closed or outlet end 36. The closed end isalso formed by sonically welding the two layers together. In oneexemplary embodiment, surface 31 of the gears of roller 14 provide asurface for securing the two layers together to provide the closed oroutlet end 36.

In accordance with one non-limiting exemplary embodiment, the forming ofthe corrugations or channels formed by the geared rollers is tapered togradually to pinch down to a flat portion on one side of the sheet. Inone exemplary embodiment, this is achieved by positioning a welding hornat the end of the rollers see FIGS. 10 and 11 such that at one end ofmedia the corrugations or channels are sealed off (exit end of thefilter) and at the opposite end (e.g., the end that will become theinlet end of the filter) the corrugations or channels are open. Onenon-limiting example of such a device for achieving this configurationis illustrated in FIG. 10. The two sheets can be bonded together on oneedge using an adhesive or in an exemplary embodiment a continuous sonicweld. In addition, the entire length of the channels are also secured orwelded to the second sheet so as to form the filtration channelsillustrated in FIGS. 4-9.

In an alternative embodiment, and if a cellulose based media is used, anembossing process is used to form the corrugations and other means ofsealing the two layers may be used other than sonic welding (e.g.,adhesives, hot melt adhesives, etc.). In this embodiment the first layeris disposed between a press and die (illustrated schematically in FIG.19) wherein the press and die have complimentary features similar tothose of geared rollers 12 and 14 to form the channels. Thereafter,another press is used to seal layer 24 thereto using an adhesive andpressing process wherein the other press is configured to sandwich media10 and 24 between the two sheets. At this step heat, if necessary, canbe provided by either the press or die.

In one exemplary embodiment, and as illustrated in FIG. 4 a sheet 37 offiltration media comprising layer 10 and layer 24 is formed. In oneexemplary embodiment, the sheet of filtration media 32 is cut into aplurality of sheets 37 each of which are secured to each other to form afilter or filtration media for use in a housing. In addition, and as onesheet is stacked onto another sheet two sets of fluid flow paths 39 and41 are formed. The fluid paths 39 are formed between layers 10 and 24 ofeach sheet, which are formed by the processes described above and herein(e.g., the channels formed in layer 10 and then as layer 24 is securedthereto). In accordance with an exemplary embodiment, fluid flow paths41 are formed as each sheet 37 is secured to each other. In an exemplaryembodiment fluid flow paths 41 are formed by the valleys formed in anupper surface 40 of first layer 10 thereafter the flow path 41 isformed, as a second layer 24 of another sheet is stacked upon uppersurface 40. Although flow paths 41 are only shown on the upper mostlayer of the filter in FIG. 6 it is understood that flow paths 41 existbetween each layer 24 and each upper surface 40 of each layer 10.

Referring now to FIGS. 5 and 6 and in order to form the finalconfiguration of a filter constructed in accordance with an exemplaryembodiment of the present invention, a strip of adhesive 38 is appliedto upper surface 40 of first layer 10 after the same has been secured tosecond layer 24 to form sheet 37. Thereafter, another sheet ispositioned on top so that a second layer 24 of one sheet is secured to afirst layer 10 of another sheet. In other words each layer 10 will besecured to a layer 24 on opposite sides, one by sonic welding and one byadhesive. Adhesive 38 is positioned at an inlet end of the filter sothat fluid flowing through the filter must first flow into fluid flowpaths 39 and then through the filtration media of the first and/orsecond layer and into fluid flow path 41 so that the filtered fluid maypass through the exit end of the filter. As illustrated, FIG. 6 shows aportion of the inlet end of the filter and FIG. 5 shows a portion of theexit end of the filter.

In this embodiment, the filter is constructed from a plurality of sheetscomprising layer 10 and layer 24 secured thereto. Accordingly, adhesive38 is disposed on upper surface 40 of layer 10 of each of the sheets tosecure the same to another sheet or more specifically, the second layer24 of another sheet. A non-limiting example of adhesive 38 is a rubberand epoxy sealant or any other equivalent adhesive capable of securingthe layers together as well as providing a fluid barrier. Although astrip of adhesive is shown it is, of course, understood that theadhesive may comprise any configuration as long as the same provides afluid barrier. It is also understood that the adhesive be positioned atthe entrance end of the filter so that the maximum amount of the filteris used for filtering of a fluid passing therethrough. In other words,if the sealant is disposed across the entire upper surface or closer tothe exit end of the filter or sheet the fluid paths between the layersof each sheet will not be provided or the available surface filter areawill be limited.

As illustrated in FIG. 6, the arrows in FIG. 6 illustrate the flow ofair being filtered, as can be seen, the media comprising the entirelength of the channels is used for filtration thus a larger amount ofsurface area is provided. In accordance with an exemplary embodiment andsince sealant 38 is disposed at the inlet end of the filter, the entirelength of the channels is used for filtration wherein either the mediaof sheet 10 or sheet 24 is the filtration barrier or media. Accordingly,each channel is used to provide a filtration surface area. Moreover, thedirection of fluid flow through the filter is substantially changed orredirected since the fluid must traverse from one of the channels toanother channel disposed between the two layers, which causesparticulates entrained in the fluid stream to drop off or be captured inthe channels of the filter.

In yet another alternative exemplary embodiment, sheets 37 may bestacked in an alternating arrangement wherein the sealed ends and openends are alternated at each end of the filter and the sealant isdisposed therebetween.

Referring now to FIGS. 7-9 another alternative exemplary embodiment isillustrated. In this embodiment, a single continuous sheet is used toform the filter. In this exemplary embodiment, and as illustrated inFIGS. 1-3 the sheet of filtration media comprising layer 10 and layer 24is formed via the forming process wherein a thermoforming process isused to form corrugations in layer 10 and thereafter layer 24 is securedthereto via a first ultrasonic horn to form the channels between the twolayers and then a peripheral edge of the two sheets is sealed via asecond ultrasonic horn to provide a sealed end of the layer offiltration media. Thereafter, a strip of adhesive 38 is disposed on theupper surface 40 of layer 10 along the inlet end 34 or non-sealed end ofthe sheet of the filtration media.

Then, the sheet is wrapped around itself so that adhesive 38 secures aportion of layer 24 to a portion of the upper surface of layer 10. Asthe sheet is wrapped around itself and secured together the two sets offluid flow paths 39 and 41 are formed. Although not specifically shownin the Figures it is understood that paths 41 are located behind thesealant or adhesive 38 between each sheet 37. The fluid paths 39 areformed between layers 10 and 24 of each sheet, which are formed by theprocesses described above and herein while fluid flow paths 41 areformed as each portion of the sheet is secured together. In an exemplaryembodiment fluid flow paths 41 are formed by the valleys formed in theupper surface 40 of first layer 10 thereafter the flow path 41 is formedas a portion of second layer 24 is wrapped around and secured to theupper surface. In accordance with an exemplary embodiment, adhesive 38is positioned at an inlet end of the filter so that fluid flowingthrough the filter must first flow into fluid flow paths 39 and thenthrough the filtration media of the first and/or second layer into fluidflow path 41 so that the filtered fluid may pass through the exit end ofthe filter.

In this embodiment, the filter is constructed from a single sheetcomprising layer 10 and layer 24 secured thereto. Thereafter, the sheetof filter media is wrapped around itself such that second layer 24 isadhered to the adhesive disposed upon the upper surface of the firstlayer.

In another alternative exemplary embodiment, the filter is formed from asheet 32 wrapped around and sealed to itself and thereafter anothersheet or a plurality of sheets are secured to the wrapped portion inaccordance with the teachings of FIGS. 5 and 6. Accordingly, and in thisembodiment the adhesive 38 is disposed on upper surface 40 of layer 10of the sheet wrapped around itself as well as each of the sheets securedto the wrapped sheet or another sheet ultimately secured to the wrappedsheet. A non-limiting example of adhesive 38 is a rubber and epoxysealant or any other equivalent adhesive capable of securing the layerstogether as well as providing a fluid barrier. Although a strip ofadhesive is shown it is, of course, understood that the adhesive maycomprise any configuration as long as the same provides a fluid barrier.It is also understood that the adhesive be positioned at the entranceend of the filter so that the maximum amount of the filter is used forfiltering of a fluid passing therethrough. In other words, if thesealant is disposed across the entire upper surface or closer to theexit end of the filter or sheet the fluid paths between the layers ofeach sheet will not be provided.

FIGS. 7-9 illustrate a filter 42 formed by wrapping and securing filtermedia 32 upon itself. In accordance with an exemplary embodiment, eachfilter 42 will be formed from a sheet of filter media 32, which is inturn formed by securing two layers together and then wrapping media 32upon itself and each filter will have a plurality of internal cavitiesextending therethrough until the sealed end 36, which improves thesurface area of the filter. In an exemplary embodiment, the mediawrapped around itself is inserted into a housing 43 having an openingfor receiving the inlet end of the filter medium and an opening for anexit end of the filter medium. One non-limiting example of anapplication for housing 43 would be an air-filer housing for a vehicleor any other application requiring an air filter. Of course, exemplaryembodiments of the present invention may be used in any type offiltering application for any type of fluid. In accordance with anexemplary embodiment the housing may have any configuration as long asan inlet opening and outlet opening is provided in order to facilitateflow through the inlet end and out the outlet end of the filter media.In other words, the housing illustrated in FIGS. 8 and 9 may compriseany alternative configuration.

As used herein, the term “filter” is intended to cover the wrapped,stacked or combination thereof of layers of the media to form an inletend and an outlet end wherein the filtering of a fluid is facilitated byusing the increased surface area of the formed media by flowing from theinlet end into the outlet end. Furthermore and as applications requireand in alternative exemplary embodiments, the term “filter” is alsointended to cover the aforementioned configurations of the mediadisposed in a housing having a corresponding inlet opening and acorresponding outlet opening wherein the filtering of a fluid isfacilitated by using the increased surface area of the formed media byflowing from the inlet end into the outlet end and the formed media isconstructed using any of the manufacturing process steps, methods, etc.disclosed herein.

As discussed, herein the media may comprise wrapped layer 32, aplurality of stacked sheets in one direction or an alternating directionor any combination thereof. Flow is facilitated through the media of themembers by sealing the areas between the members at one end (e.g., sonicwelding of end 36) and the adhesive being disposed between the layers ofthe filter as they are wrapped around themselves. Accordingly, fluid tobe filtered will flow into the inlet ends of the filter and the filteredfluid will pass through the filter media at a location behind thesealant disposed at the inlet end of the filter.

Accordingly, and due to this unique configuration more surface filterarea is provided without restricting flow since a plurality of cavitiesare provided.

As constructed, air or other fluid will flow into end 34 and then willbe filtered by the media and exit through or proximate to the outlet end36 of the filter after the air or fluid has been filtered. As shown, theinlet side comprises a plurality of inlet openings or a honeycomb styleair filter wherein a high capacity is achieved through the maximizationof the surface area of the filter media.

A prototype filter was constructed using media commercially availablefrom Hollingsworth & Vose as BW3, a 3 oz/yd² polyester non-woven media.In addition, other non-woven medias from Hollingsworth & Vose were usedincluding—BW44 oz., 7322 (high loft media) a 4 oz/yd yd² polyesternon-woven media, with a slit or channel width of approximately 6 inches.The media was formed between two geared rollers, and heated just priorto entering the rolls. The media that passes through the forming rollswas guided to the top roll, and then passes between the top roll and asonic weld horn, which welded along the length of each corrugation tosecure the corrugated sheet to the flat sheet layer as well as providethe flat closed end portion. The finished corrugated-flat sheetcombination was then rolled around itself and a rubber and epoxy sealwas used to seal between the layers on the opposite end as that whichcontained the welded seam.

Referring now to FIGS. 12-14 alternative exemplary embodiments of thepresent invention are illustrated. Here alternative configurations ofsheet 37 are illustrated. In accordance with exemplary embodiments ofthe present invention, sheets are formed using the processes and methodsdisclosed herein with varying patterns. For example, FIG. 12 illustratesa sheet 37 formed with a “herring bone” pattern, which in thisembodiment would be formed by complimentary geared rollers 12 and 14(e.g., having the herring bone configuration). As illustrated, sheet 37has a closed peripheral edge 36 and an open edge 34, which has the openends of the channels 39 extending through until the sealed edge 34. Itbeing understood that the sealed and open ends of the sheet are formedby the methods disclosed herein (e.g., ultrasonic welding, adhesives,embossing and adhesives, and combinations thereof).

FIG. 13 illustrates a curved configuration, wherein sheet 37 is formedwith curved channels or corrugations, which in this embodiment would beformed by complimentary geared rollers 12 and 14 (e.g., having thecurved configuration). As illustrated, sheet 37 has a closed peripheraledge 36 and an open edge 34, which has the open ends of the channels 39extending through until the sealed edge 34. It being understood that thesealed and open ends of the sheet are formed by the methods disclosedherein (e.g., ultrasonic welding, adhesives, embossing and adhesives,and combinations thereof).

FIG. 14 illustrates yet another configuration, wherein sheet 37 isformed with channels or corrugations only partially sealed therebetween.The channels or corrugations in this embodiment are again formed bycomplimentary geared rollers 12 and 14 however, the ultrasonic hornsealing the two layers together is configured to only make selectivecontact between the two layers. This may be achieved in one non-limitingembodiment by configuring the horn to have protrusions on the contactsurface of the horn as well as moving the horn via an X-Y positioningdevice. As shown in FIG. 14 the horn is configured to make a first setof welds 50 having a first pattern and then make a second set of welds52 having another or second pattern and thereafter the patterns arerepeated. In this embodiment, the channels or corrugations betweenlayers 10 and 24 are not completely sealed and fluid may flow as shownby the arrow in FIG. 14 however and in order to exit the filter mediathe fluid must pass through at least one layer 10 or 24. As illustrated,sheet 37 has a closed peripheral edge 36 and an open edge 34, whichincludes the open ends of the channels 39 extending through until thesealed edge 34. It being understood that the sealed and open ends of thesheet are formed by the methods disclosed herein (e.g., ultrasonicwelding, adhesives, embossing and adhesives, and combinations thereof).In addition and in this embodiment, peripheral edges 54 and 56 must becompletely sealed as opposed to the alternating patterns 50 and 52defining channels or flow paths 39 extending therethrough.

Referring now to FIGS. 15 and 16 yet another alternative exemplaryembodiment is illustrated. Here the ultrasonic horn 33 is positioned toplace the sealed end in the middle of the sheet being thermoformedbetween rollers 12 and 14 as well as being sealed together by horn 26.Thereafter, the sheet is cut down the middle to provide the sheetsillustrated in any of the aforementioned Figures.

Referring now to FIGS. 17 and 18 end views of filters or configurationsof filter media constructed in accordance with exemplary embodiment ofthe present invention are illustrated. Here the weld points betweenlayers 10 and 24 are illustrated as well as the securement of layer 24of one sheet via an adhesive to layer 10 of another sheet. In addition,the inlet end and the inlet ends or outlet ends of the filter areillustrated as well as the open ends of the fluid channels and thesealed ends of the fluid channels. Of course, the configurationsillustrated in FIGS. 17 and 18 are provided as examples and exemplaryembodiments are not intended to be limited to the specificconfigurations illustrated. FIG. 17 illustrates a stacked configurationof sheets 37 wherein the ends 34 and 36 are alternated here either endcan be provided as an inlet end of the filter. FIG. 18 illustrates astacked configuration of sheets 37 wherein the ends 34 provide the inletend of the filter. Alternatively, ends 36 can provide the inlet end ofthe filter and ends 34 can provide the outlet end.

While the invention has been described with reference to one or moreexemplary embodiments, it will be understood by those skilled in the artthat various changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

1. A filter formed by the steps of: forming a plurality of sheets offilter media, each sheet of filter media having an inlet end and anoutlet end, wherein each of the plurality of sheets of filter media areformed by the steps of: thermoforming a first layer of filtration mediato have a plurality of channels, the first layer having an upper surfaceand a lower surface; sonically welding a portion of a second layer offiltration media to the first layer of filtration media after the firstlayer is thermoformed to form the sheet of filtration media, wherein atleast one edge of the first layer is not sonically welded to at leastone edge of the second layer, wherein the sheet of filtration media hasa plurality of fluid channels each having an inlet opening at the atleast one edge of the first layer and the second layer and a sealed endat another end of the sheet; and securing the plurality of sheetstogether by applying a strip of adhesive between each upper surface ofeach first layer facing the second layer of another sheet of filtermedia stacked upon the upper surface of the first layer of thefiltration media.
 2. The filter as in claim 1, wherein the first layerof filtration media and the second layer of filtration media arenon-woven polyester materials and the sheets are secured to each otherin an alternating arrangement.
 3. The filter as in claim 1, wherein thefilter is an air filter configured to be received in a housing.
 4. Thefilter as in claim 1, wherein the strip of adhesive is a rubber andepoxy sealant disposed at the inlet end of the sheet of filter media,wherein the inlet openings are located at an inlet end of the filter. 5.The filter as in claim 1, wherein the plurality of channels are formedto have a curved or herringbone configuration.
 6. The filter as in claim1, wherein the step of thermoforming further comprises passing the firstlayer of filtration media between a pair of geared rollers each having aplurality of teeth configured to form the plurality of channels in thefirst layer of filtration media as it is passed between the pair ofgeared rollers and wherein the first layer of filtration media is apolyester non-woven media.
 7. The filter as in claim 6, wherein thefirst layer of filtration media is heated prior to it being insertedbetween the pair of geared rollers.
 8. A filter formed by the steps of:thermoforming a first layer of filtration media to have a plurality ofchannels, the first layer having an upper surface and a lower surface;sonically welding only a portion of a second layer of filtration mediato the first layer of filtration media to form a sheet of filtrationmedia having a plurality of fluid channels defined in part by theplurality of channels, each of the plurality of fluid channels having aninlet opening at one end of the sheet that is defined by another portionof the first layer that is not sonically welded to the second layer offiltration media and a sealed end at another end of the sheet; applyinga strip of adhesive to the upper surface of the first layer offiltration media; and securing the second layer to the upper surface ofthe first layer of filtration media by wrapping the sheet of mediaaround itself.
 9. The filter as in claim 8, wherein the strip ofadhesive is a rubber and epoxy sealant disposed proximate to an inletend of the filter.
 10. The filter as in claim 8, wherein the step ofthermoforming further comprises passing the first layer of filtrationmedia between a pair of geared rollers after the first layer offiltration media is heated.
 11. The filter as in claim 10, wherein thesecond layer of filtration media is generally planar in configurationand the step of sonically welding further comprises passing the firstlayer of filtration media and the second layer of filtration mediabetween one of the pair of geared rollers and a contact surface of afirst welding horn and a second welding horn, the first welding hornproviding welded portions of the plurality of fluid channels and thesecond welding horn providing the sealed end of the plurality of fluidchannels.
 12. The filter as in claim 8, wherein the first layer offiltration media and the second layer of filtration media are non-wovenpolyester materials and the step of thermoforming further comprisespassing the first layer between a pair of geared rollers each having aplurality of teeth configured to form the plurality of channels in thefirst layer of filtration media as it is passed between the pair ofgeared rollers.
 13. The filter as in claim 8, wherein the strip ofadhesive is a rubber and epoxy sealant.
 14. The filter as in claim 8,wherein the filter is an air filter configured to be received in ahousing.
 15. A filter formed by the steps of: forming a plurality ofsheets of filter media, each sheet of filter media having an inlet endand an outlet end, wherein each of the plurality of sheets of filtermedia are formed by the steps of: thermoforming a first layer offiltration media to have a plurality of channels, the first layer offiltration media having an upper surface and a lower surface;ultrasonically welding only a portion of a second layer of filtrationmedia to the first layer of filtration media to form the sheet offiltration media, the sheet of filtration media having a plurality offluid channels defined in part by the plurality of channels in the firstlayer of filtration media and each of the plurality of fluid channelshaving an inlet opening at another portion of the second layer that isnot ultrasonically welded to the second layer and a sealed end definedat the portion where the second layer is ultrasonically welded to thefirst layer and wherein the first layer of filtration media and thesecond layer of filtration media are disposed between one of a pair ofgeared rollers and a contact surface of a first welding horn and asecond welding horn, the first welding horn providing welded portions ofthe plurality of fluid channels and the second welding horn providingthe sealed end; and securing the plurality of sheets together byapplying a strip of adhesive between each upper surface of each firstlayer facing the second layer of another sheet of filter media stackedupon the upper surface of the first layer of the filtration media. 16.The filter as in claim 15, wherein the sealed end has a substantiallyflat configuration.
 17. The filter as in claim 15, wherein the filter isan air filter configured to be received in a housing.
 18. The filter asin claim 15, wherein the second layer of filtration media is a planarmember and the second layer of filtration media substantially covers thelower surface.